Package receiving and delivery system

ABSTRACT

An automated package Pickup and Receiving Station (PRS) ( 100 ) with autonomous ground vehicles (AGV) ( 18 ) are presented, which may be used to pick up, deliver and securely store packages ( 28 ), parcels, mail, prepared food, groceries or other items that may be placed in a tray, which may include an integrated container. A portal ( 10 ) facilitates loading of items into, and removal of items from, the PRS ( 100 ). Within the PRS ( 100 ), items ( 28 ) may be transported from source to destination on standardized trays ( 25 ), via a two-dimensional gantry ( 32 ) and an end of arm tool ( 22 ). The gantry ( 32 ) may be oriented for movement through a central corridor ( 21 ) in the PRS ( 100 ), with end of arm tool ( 22 ) adapted for pushing trays towards, or pulling trays from, either side of the gantry ( 32 ). Items may be stored on a tray ( 25 ) in internal shelving ( 20 ), or placed directly into an AGV ( 18 ), on either side of the PRS ( 100 ).

RELATED APPLICATIONS AND CLAIM OF PRIORITY

This patent application is a continuation of patent application Ser. No.16/758,387, filed on Apr. 22, 2020, which claims priority to, PatentCooperation Treaty (PCT) application serial number PCT/US18/59119, filedon Nov. 5, 2018, titled: PACKAGE RECEIVING AND DELIVERY SYSTEM, whichclaims priority to, and incorporates by reference, U.S. provisionalpatent application 62/581,561, titled “Package Receiving and DeliverySystem”, which was filed on Nov. 3, 2017. All of these patentapplications have the same inventors as this application.

TECHNICAL FIELD

The present disclosure relates in general to an automated package Pickupand Receiving Station (PRS) which may be used in combination withautonomous ground vehicles (AGV) to pick up, deliver and securely storeparcels for the parcel delivery industry.

BACKGROUND

With the continued growth of Internet-based commerce, parcel deliveryhas become an increasingly prevalent means of conveying goods tobusinesses and individuals alike. However, growing parcel volumespresent challenges for parcel transporters. Shippers become increasinglyreliant on parcel shipping as a mode of product distribution. Parcelrecipients may have to deal with increasing parcel volume, as well asincreased instances of returning parcels via return shipment. Meanwhile,“last mile” delivery logistics are commonly understood to represent asignificant portion of the cost and burden of parcel transport.

Various approaches have been attempted for improving the logistics ofparcel delivery. For example, Amazon™ has introduced a locker servicevia which parcels may be delivered to a secure locker at a fixed site inthe vicinity of the parcel recipient's address. The parcel recipient maythen visit the locker site at the recipient's convenience, to enter apickup code, or scan a bar code, in order to obtain access to a lockercontaining the recipient's parcel. However, such an approach requiresthe parcel recipient to travel to a locker site, which may beunavailable or inconvenient for many parcel recipients.

For these and other reasons, parcel shippers, carriers and recipientsalike may benefit greatly from opportunities to reduce the cost ofdelivery, increase the speed and efficiency of delivery, and/or provideparcel shipping participants with greater convenience and flexibility.

SUMMARY

An automated and stationery package Pickup and Receiving Station (PRS)and autonomous ground vehicles (AGVs) may be utilized to pick up,securely store and deliver items such as packages, parcels, mail,prepared food, groceries, or other items that may be placed in a tray,which may include an integrated container. The station may include atwo-dimensional gantry oriented along a central corridor. The gantry maysupport an end of arm tool for selectively engaging and disengaging fromone or more package support trays. The end of arm tool may move thepackage support trays between a central position (e.g. in which thegantry may move the tray through the central corridor), a first extendedposition extended perpendicularly outwards from the 2D gantry in a firstdirection, and a second extended position extending perpendicularlyoutwards from the 2D gantry in a second direction. The tray may includea flat platform, guide rails, and/or integrated containers.

An access portal may allow individuals, such as a delivery servicedriver or consumer, to dispense one or more packages into the PRS. Theportal may include a computer interface for, e.g., authenticating anindividual using the portal and/or identifying a package being retrievedfrom or dispensed into the PRS. A portal door may be provided. A portaltray support may support a movable package support tray proximate alower edge of the portal to facilitate dispensing of a package onto thetray by a user. The portal tray support may include a weigh scale toevaluate package weight. The portal may be positioned proximate thegantry, such that the end of arm tool may position a tray beneath theportal to receive a package. A tray and associated package may be movedby the end of arm tool and gantry from the portal, to storage shelvingwithin the PRS, and/or into an AGV. The PRS may include one or more baysfor passage of an AGV into the PRS. When within the PRS, an AGV may bepositioned proximate the gantry to facilitate automated loading andunloading of trays and packages or other items supported thereon ortherein.

In some embodiments, the end of arm tool may include pinion gears drivento engage and disengage with gear racks on the package support trays. Insome embodiments, the end of arm tool may include friction rollersdriven to engage with package support trays and pull the package supporttrays onto the end of arm tool, or push the package support trays intostationary PRS shelving or AGV package compartment shelving.

The PRS may include bays providing for navigation of AGVs into and outof the PRS. While housed within the PRS between operating periods, anAGV may recharge integrated batteries. An AGV may include a drive trainportion for autonomous navigation of the AGV, as well as a packagestorage compartment. The package storage compartment may include a firstside for automated loading of the AGV by, e.g., the PRS. The packagestorage compartment may include a second side for interaction of humans(e.g. package recipients, or individuals tendering a package to an AGV).The second side may include an array of access doors. The packagestorage compartment may be implemented without vertical separationbetween areas behind two or more adjacent access doors. Thus, packagesupport trays may be dynamically positioned within the AGV packagestorage area such that packages may take up two or more adjacent storageareas. Upon delivery, the AGV may operate to identify two or morepackage storage areas associated with a package, and open two or moredoors associated with those storage areas, thereby providing user accessto a storage area appropriately sized for a package.

Customers can add or remove packages from an array of lockers on theAGVs after their identity is securely verified. Packages picked up fromcustomers by the AGVs are returned to the PRS and unloaded with theautomated 2D gantry and transferred to shelves inside the PRS for securestorage until they are picked up by delivery drivers.

Various other objects, features, aspects, and advantages of the presentinvention and embodiments will become more apparent from the followingdetailed description of preferred embodiments, along with theaccompanying drawings in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a right perspective view of a PRS with two AGV bays.

FIG. 1B is a left perspective view of a PRS with two AGV bays.

FIG. 2 is a close up perspective view of a portal for package insertionor retrieval.

FIG. 3 is a process for parcel pickup and delivery using a PRS.

FIG. 4 is a top plan view of a PRS with top container wall removed.

FIG. 5 is a side elevation of a PRS with side container wall removed.

FIG. 6 is a schematic block diagram of a PRS, in accordance with a firstconfiguration.

FIG. 7 is a schematic block diagram of a PRS, in accordance with asecond configuration.

FIG. 8 is a perspective view of end of arm tool with box.

FIGS. 9A, 9B, 9C and 9D are progressive side views of end of arm toolmotion sequence used to load and unload tray from shelf, portal or AGV.

FIG. 10 is a detailed side view of an end of arm tool.

FIG. 11 is a perspective view of end of arm tool without tray or box.

FIG. 12 is a detailed perspective view of tray grabber on an end of armtool.

FIG. 13 is a perspective view of an end of arm tool with frictionroller-based tray grabbers.

FIG. 14 is a close up perspective view of a friction roller traygrabber.

FIG. 15 is a perspective view of a tray with package.

FIG. 16 is a side view of a tray with mail parcel container.

FIG. 17A is a first side view of an AGV for unloading or loading ofpackages during human delivery or pickup from the AGV.

FIG. 17B is an opposite side view of an AGV with rollup door forinteraction with a PRS.

FIG. 18A is a schematic block diagram of AGV control systems.

FIG. 18B is a process for delivery of a package by an AGV.

FIG. 19 is an outside perspective of a single automated roll-up door ina closed position.

FIG. 20 is an outside perspective of a single automated roll-up door inan open position, for making shelving accessible to an automated gantryand end of arm tool.

FIG. 21 is a process for operation of a PRS package portal.

DETAILED DESCRIPTION

While this invention is susceptible to embodiment in many differentforms, there are shown in the drawings and will be described in detailherein several specific embodiments, with the understanding that thepresent disclosure is to be considered as an exemplification of theprinciples of the invention to enable any person skilled in the art tomake and use the invention, and is not intended to limit the inventionto the embodiments illustrated.

A system for parcel delivery may be provided using a package Pickup andReceiving Stations (PRS). In some applications, it may be desirable toprovide a number of PRSs located in areas having a high volume of localpackage delivery. Parcels directed to a recipient within an areaserviced by the PRS may be delivered in bulk to the PRS by a parcelcarrier. The PRS may then attend to final delivery to each parcel'srecipient, preferably using an automated ground vehicle (AGV).Additionally or alternatively, consumers may access the PRS via a portalin order to retrieve packages stored in the PRS, or consumers may tenderpackages to an AGV for, e.g., subsequent retrieval by a package carrierfor further transport.

While certain embodiments and illustrations described herein refer tohandling and delivery of parcels and/or packages (which terms may beused interchangeably), it is contemplated and understood that variousembodiments and inventions described herein may be beneficially utilizedin connection with a wide variety of items, particularly items that maybe placed in standardized trays or containers for handling. Examplesinclude, without limitation: mail, parcels, packages, prepared foods,groceries, or other items that may be placed in trays or containers.Systems and methods referenced herein as handling parcels or packagesshould not be deemed limited to handling of such items, unless exclusionof other item types is expressly stated or inherent given the nature ofthe described method or apparatus.

In accordance with one exemplary embodiment, FIG. 1A illustrates a rightperspective view of a PRS 100 with two AGV access bays 16, and with oneAGV 18. The PRS 100 is housed within container 14, having top surface14A, end surface 14B, side surface 14C, opposing side surface 14D andopposing end surface 14E. Preferably, for ease of installation,container 14 is constructed having a footprint approximately the maximumsize that can be placed in a standard parking space and moved by astandard duty flatbed tow truck. Such an embodiment may then be readilytransported and installed in, for example, a remote portion of a parkinglot.

FIG. 1B is right perspective view of PRS 100 with AGV 18, furtherillustrating package portal 10 set within PRS side 14D. FIG. 2 is aclose up view of portal 10. Portal 10 is preferably set into a sidesurface of PRS 100, adjacent to end surfaces, one or more of whichcontain a bay for access by an AGV. As described further hereinbelow,portal 10 provides a mechanism for individuals, such as package deliverydrivers, to load packages into, and/or remove packages from, PRS 100.Consumers may also access portal 10, e.g. in order to retrieve packagesintended for them that are stored in the PRS, effectively using the PRSas a locker system. A computer interface 12 (preferably a touchscreencomputer) is used to enable an individual to interact with the PRS 100.For example, a delivery service driver may utilize computer interface 12to identify a package being deposited into PRS 100 via portal 10 (suchas by scanning a bar code associated with a package or photographing thepackage using a camera integrated with computer interface 12).Additionally or alternatively, a delivery service driver or consumerpackage recipient may utilize computer interface 12 to specify a packageto be retrieved from within PRS 100 and presented at portal 10 forremoval by the requesting individual.

Thus, in the illustrated embodiment, two of the six sides of PRS 100 areused for entry and exit of AGVs 18 and entry and exit of the packagesthrough the delivery driver portal 10. Using only two sides of thecontainer 14 for access to PRS 100, preferably sides that are adjacentto one another, allows for PRS 100 to be installed in a greater varietyof locations, such as a corner location in a parking lot, against abuilding, or in a corner formed by two walls.

AGV 18 is preferably an electrically-powered autonomous vehicle havinginternal package shelving, as described further below. PRS 100 maycontain both a charging station and AGV alignment mechanism for each AGVbay 16. While not in operation, or while being loaded, AGV 18 canremained docked in one of bays 16 (e.g. left bay 16A or right bay 16B)for charging.

Mechanical alignment mechanisms, such as ramps 17 (which may includeintegrated guide rails for AGV tires) as well as internal tire endstops, may be used to ensure that shelving in the AGV is located in thesame place relative to container 14, every time an AGV 18 drives into anAGV bay 16. This ensures that a 2D gantry with end of arm tool canreliably load trays into AGV 18, as described further below.

PRS 100 may be utilized in a variety of package transportationprocesses. One such process is illustrated generally in FIG. 3 , anddescribed in further detail elsewhere herein. In step S300, a parcelcarrier's delivery driver visits the PRS for delivery of one or morepackages to recipients located within an area serviced by PRS 100;packages are deposited into portal 10, via interaction with computerinterface 12. In step S310, PRS 100 stores the deposited packages ininternal shelving within PRS 100. A number of parcels may be depositedby a delivery driver for temporary storage in PRS 100. Meanwhile, thedelivery driver may also request pickup of a package already stored inPRS 100 (step S320), at which point PRS 100 may deliver the appropriatepackage from internal storage to presentation for removal at portal 10(step S325).

For final delivery to their intended recipients, parcels stored withinPRS 100 are loaded onto an AGV 18 (step S330). AGV 18 may then attend toautomated delivery of packages to recipients, and/or pickup of packagesbeing shipped out by shippers within an area serviced by the AGV (stepS340). AGV 18 may then return to PRS 100 (step S350), and parcels withinthe AGV (such as undelivered parcels or shipments tendered to AGV 18 byindividuals interacting with AGV 18 during its remote navigation) may beunloaded into PRS 100 for storage, subsequent redelivery and/ortendering to a parcel delivery driver (step S360).

FIG. 4 is a top plan view of PRS 100, with container top surface 14Aremoved to reveal structures inside. AGV 18A is docked within left bay16A; AGV 18B is docked within right bay 16B. As seen in FIG. 4 , thereceiving station design is generally symmetric with structures arrangedalong either side of a centerline, promoting maximization of storagespace and equipment reuse. A two-dimensional gantry 32 includes an endof arm tool 22, and is installed parallel to and generally along thecenterline of PRS 100 within an open central corridor 21. Gantry 32(carrying tool 22) can thereby move in two dimensions though thecenterline of container 14 to access: shelving 20 installed along bothsides of the container, the delivery driver portal 10 (illustrated hereon the PRS left side, but which may be installed on either side or onboth sides) and at least one side of each of AGVs 18A and 18B, dockedwithin bays 16A and 16B respectively on either side of PRS 100. The endof arm tool 22 can preferably interface with all these differentcomponents as if it was interfacing with any standard shelf. The AGVs,shelves and portal may be implemented in such a way as to befunctionally identical in the way that they interface with 2D gantry 32and end of arm tool 22.

In order to optimize package handling, parcels may be effectivelycontainerized on standardized carrying trays, from the point of packageloading (or unloading) via portal until the point of delivery by an AGV(or pickup by an AGV). Such an approach may increase the reliability ofpackage handling and reduce the complexity of equipment required withinPRS 100 for package handling, as end of arm tool 22 need only interfacewith a single uniform package tray structure, rather than attempting tohandle packages directly having a variety of shapes, weights and sizes.

The 2D gantry 32 and end of arm tool 22 may use symmetric motions tomove a tray with a package on top of it from the package portal 10 toany number of storage shelves 20 and then finally into a shelf on AGV18. These symmetric motions can move trays between three positions:extended towards one side of the PRS, extended towards the other side ofthe PRS, or centered for transport within central corridor 21 between asource location and destination location appropriate for a givenpackage. In connection with movement between these positions, end of armtool 22 may also selectively engage and disengage from a tray, asdescribed in further detail below.

FIG. 5 is a right side elevation of the PRS 100 configuration shown inFIG. 4 , with container surface 14C removed to expose internalstructures. The right side AGV 18B is also removed, to better illustratethe arrangement of gantry 32 relative to an AGV 18A. Gantry 32 includesupper rail 32A near the top of container 14, and lower rail 32B near thebottom of container 14. Rails 32A and 32B extend horizontally forsubstantially the length of container 14. Rails 32A and 32B are therebypositioned to allow a maximum range of travel of end of arm tool 22throughout container 14, maximizing the area available for shelving 20(and therefore, the package storage capacity of PRS 100). For example,shelving posts 20A may be provided above the height of AGV 18, within aportion of PRS 100 in which AGVs may travel, thereby allowing storage ofpackages above AGV 18 within container 14. To the extent that packagesare moved within PRS 100 on standard package trays, shelving 20 may beformed from posts having a number of slots along their length forengagement of package trays at varying elevations. For example, edges ofpackage tray 25 are engaged with storage shelving rails 20B and 20C tostore package 28.

While further details of AGV are described below, AGVs may includeinternal shelving for storage of packages during transport. On one side,facing the centerline of PRS 100 when AGV 18 is positioned within bay16, a roll-up door may be opened to expose the AGV's internal storageshelving. Preferably the AGV storage shelving will have a similarconstruction to stationary PRS shelving 20, such that gantry 32 and endof arm tool 22 can operate to move a package tray 25 (and a packageresting thereon) from PRS shelving 20 (or directly from driver portal10) into an AGV 18 (e.g. in step S230). For example, AGV 18A includesroll up door (illustrated in a retracted position in FIG. 5 ) positionedon a side of AGV 18A facing the centerline of PRS 100 (and thus facinggantry 32). Use of a roll up door in such an application allows a lowprofile that not only maximizes storage space within the AGV and abovethe AGV, but also reduces the overall footprint required for PRS 100, asPRS 100 need not accommodate clearance for opening of swinging doors onAGVs 18A and 18B.

The PRS structure illustrated in FIGS. 4 and 5 may thus be utilized toimplement, e.g., steps S300-S330 and S360 in the process of FIG. 3 . Forexample, in step S300, end of arm tool 22 may deliver a package tray 25for insertion into shelving receptacles aligned with the bottom edge ofdriver delivery portal 10. After a parcel delivery service driverinserts a package into portal 10, end of arm tool 22 may pick up thetray 25, moving the tray into the center position within centralcorridor 21, at which point gantry 32 moves the tray to a desiresstorage location within shelving 20, at which time end of arm tool 22may again extend, to insert edges of tray 25 into shelving rails at thedesired storage location (step S310). Likewise, in step S320, when aparcel delivery service driver seeks to receive a package from the PRS,gantry 32 may position end of arm tool 22 at a location within shelving20 at which a tray 25 resides holding the desired package, at whichpoint end of arm tool 22 may retrieve the tray 25, with gantry 32 thenmoving tray 25 to the location of driver portal 10. At that point, theparcel delivery service driver may open portal 10 and retrieve thepackage from tray 25. Similarly, for loading of an AGV in step S330,gantry 32 may move tool 22 to a position within shelving 20 containing atray 25 holding a package desired for loading into AGV 18; tool 22 mayretrieve the tray 25 and move it into a center position within corridor21, at which time gantry 32 moves tray 25 and the package residingthereon to a location proximate an open shelf space in AGV 18, and endof arm tool 22 moves tray 25 and its associated package into AGV 18.Unloading of AGV 18 in step S360 may be accomplished similarly, withtool 22 removing a tray 25 and an associated package from AGV 18, gantry32 moving the tray 25 to a desired storage location within shelving 20,and tool 22 inserting tray 25 into the desired shelving location.

FIGS. 6 and 7 show alternative PRS configurations in simplified blockdiagram, with portal 10, shelves 20, gantry 32, end of arm tool 22, AGVs18 and AGV bays 16. FIG. 6 illustrates the box configuration describedin FIGS. 4 and 5 , with two AGV entry bays 16A and 16B on a common side14B of the PRS. However, the AGV locations, shelving, and portals are inlarge part interchangeable within a PRS, and can be configured tooptimize the desired ratio of shelving to AGVs to portals givenparticular operating conditions. The AGVs can be either first-in-lastout (FILO) or first-in-first-out (FIFO) depending on the number of AGVsand the location in which the PRS is installed. However, regardless ofconfiguration, the AGVs, shelving and portals are preferably symmetricabout gantry 32. Symmetry of the box may be important to the extent thatthe most expensive component of PRS 100 may be the linear actuatorswhich make up the 2D gantry 32. In that circumstance, it may beimportant that the utilization of the linear actuators is maximized byenabling as much of the PRS as possible to be serviced by a single 2Dgantry.

FIG. 6 illustrates a PRS configuration where AGVs are in a FILOconfiguration. Specifically, an AGV may pull into a bay 16A or 16B, andoptionally remain in position while other AGVs access other bays. In theevent that multiple AGVs pull into a single bay, the first AGV into eachbay must wait until a following AGV has been loaded and removed from thebay. This configuration requires clearance on the outside of the PRS onat least two sides. This clearance is needed to enable access to theside of package portal 10 and to allow ground vehicles to exit and enterthe PRS via bays 16A and 16B.

FIG. 7 illustrates an alternative, first in first out (FIFO) AGVconfiguration. and requires clearance on a minimum of three sides on theoutside of PRS 100. The configuration makes it easier for AGVs to enterand exit the PRS because an AGV 18 pulls straight into a first bay 16Cin container surface 14B, continues driving straight through the PRS toa second AGV position, and exits bay 16D on opposing end 14E. Therefore,AGVs may exit in the order in which they enter. However, the FIFOconfiguration of FIG. 7 requires clearance on a minimum of three sidesof the outside of the PRS: side 14B for AGV entrance, side 14E for AGVexit, and side 14C for one or more driver portals 10.

FIG. 8 is an upper perspective view of end of arm tool 22, with a tray25 and package 28 loaded thereon. As described above, end of arm tool 22is used to pull out and push in package trays 25 in a motionperpendicular to the motion of the 2D gantry 32. The end of arm tool issymmetric such that tray can be pushed onto or pulled off a shelf oneither side of the 2D gantry. Packages of various sizes 28 are placed ona standardized tray 25. In some embodiments, the standard tray 25 mayinclude a gear rack along the side of the tray. The racks mounted to thetray 25 may then be grabbed by pinion gears 34 at each corner of the endof arm tool 22. These pinion gears 34 grip the gear rack and move thetray back and forth perpendicular to the motion of the 2D gantry. Theend of arm tool 22 also has rails (described further below) which allowthe tray to slide smoothly along the end of arm tool 22 perpendicular tothe motion of the 2D gantry 34.

FIGS. 9A-9D illustrate the motion that allows end of arm tool 22 (e.g.using pinion gears 34) to engage with tray 25 (e.g. rack portions),while tray 25 is supporting package 28, thereby moving package 28 on togantry 32 for transport. In FIG. 9A, end of arm tool 22 starts in aposition such that the 2D gantry 32 (not shown in FIGS. 9A-9D) is freeto translate up/down and left/right along a central corridor 21 withinPRS 100, clearing the front of shelving 20. Once the 2D gantry 32 hasmoved the end of arm tool 22 into position in front of a tray to beretrieved, then a linear actuator 46 can move the pinion gears 34 thatare proximate the tray, forward or backward such that pinion gears 34can engage with the racks mounted on tray 25 (FIG. 9B). When the rackand pinion are engaged, end of arm tool 22 can pull tray 25 onto the endof arm tool 22, as illustrated in FIG. 9C. Finally, the linear actuator46 can pull the end of arm tool 22 back into the position seen in FIG.9D such that end of arm tool 22 is clear of shelf 20 and 2D gantry 34 isfree to translate within central corridor 21. This same sequence occursin the opposite direction to allow the end of arm tool 22 to push tray25 onto a shelf, whether that shelf is within the PRS stationary storagearea 20, at portal 10, or on an AGV 18. Analogous sequences of motionmay be implemented in embodiments utilizing friction rollers to engagewith trays, as described further below.

FIG. 10 is the side view of the end of arm tool 22. The standard tray 25slides on rail 48 (FIG. 11 ) and is gripped on two sides by pinion gears34. The end of arm tool 22 is mounted onto the 2D gantry 34 usingmounting point 44. Linear actuator 46 enables portions of end of armtool 22 (including pinion gears 34) to move back and forth to grip atray and pull it onto end of arm tool 22, or to release a tray and pushit out towards a shelf, towards portal 10 or into an AGV. Drive belt 50powers rotation of pinion gears 34.

FIG. 11 is an upper perspective view of end of arm tool 22, with no trayengaged. A single steel plate 52 is utilized to locate variouscomponents relative to one another, including tray slide rails 48,pinion gears 34, and mounting point 44.

FIG. 12 is a close up perspective view of a mechanism for end of armtool 22 to engage with a package tray, utilizing a pinion gear, bearingblock assembly and drive pulley. The pinion gear 34 engages a rackmounted on the side of a tray 25, as pictured in FIG. 13 . Limitswitches may signal when the tray is in position and the pinion gear 34engages with the rack mounted to the edge of the tray. The pinion gear34 is driven by a timing belt pulley 60. A shaft 61 is held in place bybearing block 54 and the rail 48 on which the standard tray sits.

In some embodiments, the rack and pinion gear assembly illustrated in,e.g., FIG. 12 , can be replaced by a friction roller that grips thesides of a tray with friction to push and pull the tray back and forth.While friction roller embodiments may, in extreme circumstances or eventof malfunction, be more susceptible to slippage during a tray loading orunloading operation, use of friction rollers may avoid risk of impropermeshing of pinion gears with a tray rack, which may cause equipmentdamage, accelerated wear, mechanical breakage and/or system malfunction.Slippage provided by friction rollers may, in some circumstances,encourage a tray to align itself during engagement and thus provide moretolerant of misalignment. Thus, in many embodiments, use of frictionrollers may be desirable or even preferred.

FIG. 13 illustrates a perspective view of an exemplary end of arm tool1300 employing a friction roller mechanism to engage and move a tray.Rollers 1310 are positioned at each corner of tool 1300, such thatroller 1310A and 1310B may operate to pull or push a tray in direction1350, while rollers 1310C and 1310D may operate to pull or push a trayin direction 1360. During engagement with tool 1300, trays are supportedby rails 1315. Side rollers 1320 facilitate smooth motion of trays ontoand off of tool 1300. Multiple base rollers 1325 may be mounted to, andextend slightly above, support plate 1330 in order to further facilitatesmooth motion of a tray onto and off of tool 1300. Mounting point 1340enables mounting of tool 1300 on 2D gantry 32. Similarly, to the rackand pinion embodiment described above, a linear actuator (not shown) mayoperate to advance rollers 1310 towards or away from a package tray,while drive belts may rotate rollers 1310 to push or pull a tray. FIG.14 is a partial closeup perspective view of friction roller mechanism1310D. Roller 1310D rotates on shaft 1380 retained in bearing block1370, and is driven by drive belt 1375.

Rack and pinion or friction roller mechanisms may be beneficially usedat least in part because they can be used to make a symmetric end of armtool that can access both sides of the gantry, thereby maximizingutilization of the costly 2D gantry and reducing the overall cost perpackage managed by the PRS.

FIG. 15 is an upper perspective view of a tray 25 supporting a typicalpackage 28. Each tray 25 can hold packages of different sizes. The trayhas a lip 27 which prevents packages 28 from sliding off tray 25 whenmoving between package portal 10, tray shelves 20 and AGVs 18. Opposingsides 25A and 25B may include structures to facilitate engagement withan end of arm tool. For example, in rack-and-pinion embodiments of endof arm tool 22, tray 25 may include gear racks 29 on opposing sides 25Aand 25B, for engagement with end of arm tool pinion gears 34. Infriction roller-based embodiments, tray 25 may optionally includetextured coatings or machined surfaces on sides 25A and 25B to increasethe strength and reliability of engagement between tray 25 and an end ofarm tool such as tool 1300.

While certain embodiments described herein utilize a tray having arelatively flat bottom surface, open above it, for supporting an itembeing handled, it is contemplated and understood that in otherembodiments, a tray may include additional structure for supportingand/or containing items being stored and transported. For example, atray may form an enclosed or contained area, such as via the inclusionof side surfaces and a top surface. Such closed container-based traysmay be particularly beneficial in certain applications, such astransporting collections of loose items. An enclosed tray structure mayalso be beneficial, for example, in transporting groceries orready-to-eat food items that may impact a PRS, AGV or other transportedparcels through release of aromas, heat or steam. Yet anotherapplication is as follows:

Automated Mail or Parcel Delivery

While embodiments described herein may be beneficially employed fordelivery of boxes and other packages already contained in easily-handledpackaging, additionally or alternatively, embodiments may be effectivelyutilized for efficient and automated delivery of mail or other types ofparcels or items, including items that may be small, loose or otherwisenot easily handled. For example, with regard to mail, such use cases maybe particularly effective for use with individuals who may not requiredaily delivery of mail, but who instead may prefer to aggregate postalmail and arrange for delivery at desired times and locations. Forexample, mail may be delivered to a PRS and stored in the PRS withinpostal mailbox containers sized for support on a standard tray 25,taking up the space of one small, medium or large parcel.

FIG. 16 illustrates a front view of an array of lockers 62 within acontainer, supported on a parcel tray 25. In some embodiments, array oflockers 62 may be within a single loose container item placed on a tray25; in other embodiments, array of lockers 62 may be within a containerthat is integrally attached to tray 25, to form an integrated traystructure that has one or more enclosed compartments. In eithercircumstance, a person delivering items, such as mail, can load theitems into each locker. The array of lockers 62 in a container on a traycan then be loaded into a AGV, similarly to other trays containingparcels as described elsewhere herein, such that the items may bedelivered to a recipient's location, within the array of lockers 62, ata time that it is requested by the recipient, similarly to the deliveryof packages described above. In particular, a loose array of lockers 62may be pre-loaded with items for delivery and then deposited into PRS100 through portal 10 onto a separate tray 25. Likewise, an array oflockers 62 may be previously stored within PRS 100 (potentially as anintegrated container-based tray structure), and transported to portal 10by gantry 32 for loading of items into the lockers by a user throughportal 10. Tray 25 and items loaded into array of lockers 62 can then bestored in PRS 100 in a storage shelf 20. When delivery of such items isrequested, tray 25 containing array of lockers 62 within a container maybe transferred to an AGV 18 for automated delivery to the intendedrecipient.

AGV Design

In some embodiments, an AGV design may be utilized having an array ofsmall lockers for package storage. FIG. 17A shows a detailed side viewof such an AGV 18. Package recipients may interact with a first side1700 of AGV 18. A lower portion 1710 houses the AGV's drivetrain andoperating logic, and supports parcel storage compartment 1720. Side 1700of parcel storage compartment 1720 includes an array of doors 1730,1732, 1734, 1740, 1742, 1744, 1750, 1752, and 1754. Parcel storagecompartment 1720 may be divided into small lockers via placement oftrays 25 internally within the compartment, at locations between twoadjoining doors in the array of doors.

While AGV 18 is illustrated having a three by three array of doors, itis contemplated and understood that door arrays of differing sizes maybe utilized in different embodiments. Other configurations may includean array of 1 by M small doors in a single column, with any number N ofcolumns, thus forming an arbitrary array of M by N small doors. Eachdoor includes an electronically-actuated lock and/or release, controlledby operating logic, to allow package recipients to remove packages frombehind select doors upon delivery. Each door can also preferably beautomatically opened and securely closed by the AGV without humanassistance, which may be critical in many applications as individualsreceiving deliveries and inputting a package may not remember to closethe locker. Navigation of an AGV with an open locker door may causesafety challenges (e.g. risking hitting passersby or nearby structureswith open locker doors), potential damage to the locker doors and AGV,and/or potential risk of loss to the extent transported items fall outof an unsecured access door.

FIG. 17B illustrates a side view of a second side 1701 of AGV 18, withan overhead rolling door in an open position to reveal shelving andpackages loaded therein. Preferably, package recipients will interactwith AGV 18 via side 1700, while a PRS (via a 2D gantry and end of armtool) will load and unload AGV 18 via opposite side 1701. By separatingthe sides of AGV 18 with which humans interact and with which machines(i.e. PRS 100) interact, each portion of AGV 18 may be optimized for aspecific use case. For example, side 1700 of package compartment 1720may include stops to prevent trays 25 from sliding outwards or otherwisemoving during access by a package recipient. Meanwhile, side 1701 mayinclude tapered shelve guides promoting reliable insertion and removalof trays 25 to or from shelf supports within compartment 1720, atpotential locations proximate a lower edge of each access door1730-1754; thus, even in the event of inaccuracy of positioning ofend-of-arm tool 22 within PRS 100, relative to compartment 1720, duringloading or unloading. Preferably, the shelving within compartment 1720is identical in design to shelving 20 within PRS 100, such that nospecial motions or design considerations of the gantry or the end of armtool are required when interacting with the AGV.

Multiple doors from amongst doors 1730-1754 may be configured to opensimultaneously in different combinations in order to provide recipientswith access to packages of different sizes, including packages having aheight that exceeds the height of a single door. In such embodiments,AGV side 1700 preferably lacks horizontal divisions between accessdoors, such that multiple doors may be opened at once to present anopening into package storage compartment 1720 having a height that is amultiple of a single door height. For example, if a large package 1770is loaded into an end compartment, then during delivery to the packagerecipient, three doors 1730, 1732 and 1734 may be electronicallyunlocked for simultaneous opening to allow access to, and easy removalof, the large package 1770. Similarly, when a medium package 1775 isloaded, then two doors 1740 and 1742 may be opened simultaneously duringpackage delivery. Finally, if a small package 1780 is loaded, then asingle door corresponding to the package location (in this case, door1750) may be opened during delivery. Because compartment 1720 ispreferably undivided within any given column of package storagelocations (with movable trays each supporting a particular package andserving to divide the column into one or more package storagelocations), this arrangement allows a high degree of flexibility in themix of package sizes that may be loaded into a particular AGV. Packagesmay be limited in width and depth by the size of a locker or associatedtray, but with a height limited only by the total height of the array.Such flexibility may be critical, in many application, to maximizeutilization of an AGV and achieve optimal unit delivery economics, whileallowing handling of a wide variety and varying mix of package sizes.

FIG. 18A is a simplified schematic block diagram of systems that may beutilized to support the above-described operation of AGV 18. Controller1800 interacts with data storage 1810 to, amongst other things, executeapplication logic including operating system 1810A, package compartmentapplication logic 1810B, and also to access stored data such as packagedata 1810C, which may include details concerning packages loaded intoAGV 18 (such as, without limitation, package size, intended deliverylocation, and intended recipient). Navigation systems 1820 enableautonomous navigation of AGV 18 between, e.g., PRS 100 and a packagerecipient's location. Access door control 1830 enables controller 1800to, e.g., actuate locks and/or latches for package access doors1730-1754. A man machine interface (MMI) 1840 may be provided forenabling package recipients to directly interact with AGV 18.

FIG. 18B illustrates an exemplary process for delivery of a package byAGV 18. In step S1850, AGV 18 autonomously navigates, using navigationsystems 1820, to a location associated with a recipient designated for apackage stored within package storage compartment 1720. In step S1852,AGV 18 identifies the presence of the package recipient, such as throughinteraction with the recipient via MMI 1840. In step S1854, controller1800 queries package data 1810C to identify one or more locations withinstorage compartment 1720 associated with one or more packages designatedfor delivery to the recipient identified in step S1852. As describedabove, in the event that the height of a package exceeds the height of asingle package access door, multiple contiguous locations may beassociated with a single package. Additionally or alternatively, arecipient may have multiple packages located in multiple separate smalllockers. In step S1856, controller 1800 interacts with access doorcontrols 1830 to electronically open and close access doorscorresponding to locations identified in step S1854, via which arecipient may retrieve one or more packages.

In some embodiments, as illustrated in FIGS. 17B and 20 , a verticalcolumn of AGV access doors may be without fixed horizontal divisions,such that as much as an entire column of access door spaces may becombined into a single storage compartment depending on placement ofmovable package support trays. However, it is contemplated andunderstood that in other embodiments, package storage compartment 1720may include at least some fixed divisions. However, preferably, at leasttwo contiguous vertically-arranged access doors are provided withouthorizontal divisions, such that they may be adaptively combined asneeded to provide larger or smaller storage areas.

FIGS. 19 and 20 show a detailed view of a single automated roll-up doorproviding access to an AGV package storage compartment during loading bya PRS. In FIG. 19 , roll up door 1900 is shown in a closed position, tosecurely store packages within compartment 1720. FIG. 20 shows AGV 18with roll up door 1900 in an open position, rolled up into AGV topcompartment 2000, exposing shelving inside the AGV such that it may betreated by 2D gantry 34 and end of arm tool 22 exactly like stationaryshelves 20 inside PRS 100 (e.g. for loading and/or unloading of packages1800, 1805 and 1810). Roll-up door 1900 thus provides a low profilesolution to make the shelving inside the AGV accessible to the PRS.

Use of PRS Portals

As mentioned above, PRS 100 includes one or more portals 10 to enableparcel delivery service drivers to load packages into, or unloadpackages from, PRS 100. Referring back to FIG. 2 , a user may accesstouch screen computer 12 with integrated camera in order to, forexample, identify the user to PRS 100, identify a package to bedeposited into PRS 100, and/or identify a package that the user desiresto remove from PRS 100. FIG. 21 illustrates an exemplary process fordepositing a package into PRS 100, using portal 10. In step S2100, theuser authenticates with PRS 100 using computer 12, such as via loggingin with username and password, scanning a QR code, or tapping an RFIDbadge. In step S2110, the user identifies a package to be deposited intoPRS 100, e.g., by optically scanning a bar code associated with thepackage's delivery label. In step S2120, door 11 is released foropening. In step S2130, the user inserts a package 28 through portal 10onto tray 25. In step S2140, the user closes door 11, and door 11 islocked, at which point the package is preferably weighed (e.g. via aweigh scale integrated into portal tray support 20D (FIG. 5 )), measuredand photographed. Preferably, the shipping labels are also digitized toconfirm package identify. In step S2150, PRS 100 retrieves tray 25,transports tray 25 and the package supported by it through PRS centralcorridor 21 towards a desired storage destination, and then loads tray25 and its supported package into the desired destination (such asshelving 20 or directly into the package compartment of an AGV dockedwithin PRS 100). In step S2160, 2D gantry 32 and end of arm tool 22position an empty tray 25 into a portal tray support 20D at a levelaligned with a lower edge of portal 10, such that portal 10 is ready forloading of another package. Preferably, for safety, door 11 remainslocked at all times when trays are moving in and out of portal 10.

While certain embodiments of the invention have been described herein indetail for purposes of clarity and understanding, the foregoingdescription and Figures merely explain and illustrate the presentinvention and the present invention is not limited thereto. It will beappreciated that those skilled in the art, having the present disclosurebefore them, will be able to make modifications and variations to thatdisclosed herein without departing from the scope of any appendedclaims.

What is claimed is:
 1. A package delivery and receiving system.